Deposited material structure with integrated component

ABSTRACT

A method for forming a metallic structure having a secondary component includes positioning the secondary component on a main formation surface of a main tool, the main formation surface corresponding to a desired shape of a first layer of material. The method also includes depositing a layer of material on the secondary component and the main formation surface using a cold-spray technique such that the layer of material bonds to the secondary component. The method also includes removing the layer of material and the secondary component to form the metallic structure.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No.15/388,223, filed Dec. 22, 2016 for “DEPOSITED MATERIAL STRUCTURE WITHINTEGRATED COMPONENT”, which is hereby incorporated by reference herein.

FIELD

The present disclosure is directed to a system and a method for creationof a metallic structure having a pre-formed integrated componentattached thereto.

BACKGROUND

Gas turbine engines include multiple components, a portion of which areformed as sheet structures. These sheet structures are currently hot orcold formed using dies. The dies include a relatively durable materialthat is capable of withstanding the temperature, pressure, and otherloads applied to the die via the selected forming operation. Thematerial used in the dies may be relatively expensive. Furthermore,formation of dies is a relatively time-consuming and expensive process.The time and expense of forming the dies increases as the complexity,such as complex contours and size, of the desired part increases.

SUMMARY

Disclosed herein is a method for forming a metallic structure having asecondary component. The method includes positioning the secondarycomponent on a main formation surface of a main tool, the main formationsurface corresponding to a desired shape of a first layer of material.The method also includes depositing a layer of material on the secondarycomponent and the main formation surface by cold spraying the layer ofmaterial such that the layer of material bonds to the secondarycomponent. The method also includes removing the layer of material andthe secondary component to form the metallic structure.

In any of the foregoing embodiments, the secondary component has abonding surface configured to receive the layer of material, the bondingsurface being textured to enhance bonding with the layer of material.

Any of the foregoing embodiments may also include positioning asecondary tool on the secondary component such that the layer ofmaterial is at least partially deposited on the secondary tool.

Any of the foregoing embodiments may also include removing the secondarytool to form a space between at least a portion of the secondarycomponent and the layer of material.

In any of the foregoing embodiments, removing the secondary toolincludes forming a hole in the layer of material and leaching thesecondary tool from the layer of material through the hole via at leastone of etching the secondary tool or melting the secondary tool.

Any of the foregoing embodiments may also include sealing the hole afterremoving the secondary tool.

In any of the foregoing embodiments, the main formation surface definesa volume having a shape corresponding to the secondary component, andpositioning the secondary component on the main formation surfaceincludes positioning the secondary component in the volume defined bythe main formation surface.

Also disclosed is a system for forming a metallic structure having asecondary component. The system includes a main tool having a mainformation surface corresponding to a desired shape of the metallicstructure. The system also includes a secondary component configured tobe positioned on the main formation surface. The system also includes acold-spray gun configured to output a gas including particles of amaterial towards the main formation surface and the secondary componentat a velocity sufficiently great to cause the particles of the materialto bond together and to the secondary component on the main formationsurface to form a layer of material, resulting in the metallic structurewith the secondary component attached thereto.

In any of the foregoing embodiments, the secondary component has abonding surface configured to receive the layer of material, the bondingsurface being textured to enhance bonding with the layer of material.

Any of the foregoing embodiments may also include a secondary toolconfigured to be positioned on the secondary component such that thecold-spray gun is configured to deposit at least a portion of the layerof material on the secondary tool.

Any of the foregoing embodiments may also include a device for removingthe secondary tool to form a space between at least a portion of thesecondary component and the layer of material.

Any of the foregoing embodiments may also include a hole-forming deviceconfigured to form a hole in the layer of material wherein the devicefor removing the secondary tool is configured to remove the secondarytool via the hole in the layer of material.

In any of the foregoing embodiments, the main formation surface definesa volume having a shape corresponding to the secondary component andconfigured to receive the secondary component.

Also described is a metallic structure having a secondary componentattached thereto. The metallic structure with the secondary component isformed by a method that includes positioning the secondary component ona main formation surface of a main tool, the main formation surfacecorresponding to a desired shape of a first layer of material. Themethod also includes depositing a layer of material on the secondarycomponent and the main formation surface by cold spraying the layer ofmaterial such that the layer of material bonds to the secondarycomponent. The method also includes removing the layer of material andthe secondary component to form the metallic structure.

In any of the foregoing embodiments, the secondary component has abonding surface configured to receive the layer of material, the bondingsurface being textured to enhance bonding with the layer of material.

In any of the foregoing embodiments, the method further comprisespositioning a secondary tool on the secondary component such that thelayer of material is at least partially deposited on the secondary tool.

In any of the foregoing embodiments, the method further includesremoving the secondary tool to form a space between at least a portionof the secondary component and the layer of material.

In any of the foregoing embodiments, removing the secondary toolincludes forming a hole in the layer of material and leaching thesecondary tool from the layer of material through the hole via at leastone of etching the secondary tool or melting the secondary tool.

In any of the foregoing embodiments, the method further comprisessealing the hole after removing the secondary tool.

In any of the foregoing embodiments, the main formation surface definesa volume having a shape corresponding to the secondary component, andpositioning the secondary component on the main formation surfaceincludes positioning the secondary component in the volume defined bythe main formation surface.

The foregoing features and elements may be combined in variouscombinations without exclusivity, unless expressly indicated otherwise.These features and elements as well as the operation thereof will becomemore apparent in light of the following description and the accompanyingdrawings. It should be understood, however, the following descriptionand drawings are intended to be exemplary in nature and non-limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features will become apparent to those skilled in the art fromthe following detailed description of the disclosed, non-limiting,embodiments. The drawings that accompany the detailed description can bebriefly described as follows:

FIG. 1 is a schematic cross-section of a gas turbine engine, inaccordance with various embodiments;

FIG. 2 is a flowchart illustrating a method for forming a sheetstructure usable in the gas turbine engine of FIG. 1 using a cold-spraytechnique, in accordance with various embodiments;

FIG. 3 is a block diagram illustrating a system for forming a sheetstructure using a cold-spray technique, in accordance with variousembodiments;

FIG. 4A is a drawing of a tool used for forming a sheet structure usinga cold-spray technique, in accordance with various embodiments;

FIG. 4B is a drawing of the tool of FIG. 4A having an interface coatingfor receiving a cold-spray deposit, in accordance with variousembodiments;

FIG. 4C is a drawing of a sheet structure using the tool and interfacecoating of FIG. 4B, in accordance with various embodiments;

FIG. 5A is a drawing of a tool having a recess in a formation surfacefor forming a sheet structure with a feature having a greater thicknessrelative to other portions of the sheet structure, in accordance withvarious embodiments;

FIG. 5B is a drawing of the sheet structure with the feature formedusing the tool of FIG. 5A, in accordance with various embodiments;

FIG. 6A is a flowchart illustrating a method for forming a metallicstructure having a secondary component integrally attached thereto usinga cold-spray technique, in accordance with various embodiments;

FIG. 6B is a flowchart illustrating a method for removing a secondarytool from a space between a layer of material and a secondary component,in accordance with various embodiments;

FIGS. 7A-7D are drawings illustrating various steps for forming ametallic structure having a secondary component integrally attachedthereto using a cold-spray technique, in accordance with variousembodiments; and

FIGS. 8A-8C are drawings illustrating various steps for forming ametallic structure having a secondary component integrally attachedthereto using a cold-spray technique, in accordance with variousembodiments.

DETAILED DESCRIPTION

All ranges and ratio limits disclosed herein may be combined. It is tobe understood that unless specifically stated otherwise, references to“a,” “an,” and/or “the” may include one or more than one and thatreference to an item in the singular may also include the item in theplural.

The detailed description of various embodiments herein makes referenceto the accompanying drawings, which show various embodiments by way ofillustration. While these various embodiments are described insufficient detail to enable those skilled in the art to practice thedisclosure, it should be understood that other embodiments may berealized and that logical, chemical, and mechanical changes may be madewithout departing from the spirit and scope of the disclosure. Thus, thedetailed description herein is presented for purposes of illustrationonly and not of limitation. For example, the steps recited in any of themethod or process descriptions may be executed in any order and are notnecessarily limited to the order presented. Furthermore, any referenceto singular includes plural embodiments, and any reference to more thanone component or step may include a singular embodiment or step. Also,any reference to attached, fixed, connected, or the like may includepermanent, removable, temporary, partial, full, and/or any otherpossible attachment option. Additionally, any reference to withoutcontact (or similar phrases) may also include reduced contact or minimalcontact. Cross hatching lines may be used throughout the figures todenote different parts but not necessarily to denote the same ordifferent materials.

As used herein, “aft” refers to the direction associated with theexhaust (e.g., the back end) of a gas turbine engine. As used herein,“forward” refers to the direction associated with the intake (e.g., thefront end) of a gas turbine engine.

As used herein, “radially outward” refers to the direction generallyaway from the axis of rotation of a turbine engine. As used herein,“radially inward” refers to the direction generally towards the axis ofrotation of a turbine engine.

In various embodiments and with reference to FIG. 1, a gas turbineengine 20 is provided. The gas turbine engine 20 may be a two-spoolturbofan that generally incorporates a fan section 22, a compressorsection 24, a combustor section 26 and a turbine section 28. Alternativeengines may include, for example, an augmentor section among othersystems or features. In operation, the fan section 22 can drive coolant(e.g., air) along a bypass flow path B while the compressor section 24can drive coolant along a core flow path C for compression andcommunication into the combustor section 26 then expansion through theturbine section 28. Although depicted as a two-spool turbofan gasturbine engine 20 herein, it should be understood that the conceptsdescribed herein are not limited to use with two-spool turbofans as theteachings may be applied to other types of turbine engines includingturbojet, turboprop, turboshaft, or power generation turbines, with orwithout geared fan, geared compressor or three-spool architectures.

The gas turbine engine 20 may generally comprise a low speed spool 30and a high speed spool 32 mounted for rotation about an engine centrallongitudinal axis A-A′ relative to an engine static structure 36 orengine case via several bearing systems 38, 38-1, and 38-2. It should beunderstood that various bearing systems 38 at various locations mayalternatively or additionally be provided, including for example, thebearing system 38, the bearing system 38-1, and the bearing system 38-2.

The low speed spool 30 may generally comprise an inner shaft 40 thatinterconnects a fan 42, a low pressure compressor 44 and a low pressureturbine 46. The inner shaft 40 may be connected to the fan 42 through ageared architecture 48 that can drive the fan 42 at a lower speed thanthe low speed spool 30. The geared architecture 48 may comprise a gearassembly 60 enclosed within a gear housing 62. The gear assembly 60couples the inner shaft 40 to a rotating fan structure. The high speedspool 32 may comprise an outer shaft 50 that interconnects a highpressure compressor 52 and high pressure turbine 54. A combustor 56 maybe located between high pressure compressor 52 and high pressure turbine54. A mid-turbine frame 57 of the engine static structure 36 may belocated generally between the high pressure turbine 54 and the lowpressure turbine 46. Mid-turbine frame 57 may support one or morebearing systems 38 in the turbine section 28. The inner shaft 40 and theouter shaft 50 may be concentric and rotate via bearing systems 38 aboutthe engine central longitudinal axis A-A′, which is collinear with theirlongitudinal axes. As used herein, a “high pressure” compressor orturbine experiences a higher pressure than a corresponding “lowpressure” compressor or turbine.

The airflow of core flow path C may be compressed by the low pressurecompressor 44 then the high pressure compressor 52, mixed and burnedwith fuel in the combustor 56, then expanded over the high pressureturbine 54 and the low pressure turbine 46. The turbines 46, 54rotationally drive the respective low speed spool 30 and high speedspool 32 in response to the expansion.

The gas turbine engine 20 may be, for example, a high-bypass ratiogeared engine. In various embodiments, the bypass ratio of the gasturbine engine 20 may be greater than about six (6). In variousembodiments, the bypass ratio of the gas turbine engine 20 may begreater than ten (10). In various embodiments, the geared architecture48 may be an epicyclic gear train, such as a star gear system (sun gearin meshing engagement with a plurality of star gears supported by acarrier and in meshing engagement with a ring gear) or other gearsystem. The geared architecture 48 may have a gear reduction ratio ofgreater than about 2.3 and the low pressure turbine 46 may have apressure ratio that is greater than about five (5). In variousembodiments, the bypass ratio of the gas turbine engine 20 is greaterthan about ten (10:1). In various embodiments, the diameter of the fan42 may be significantly larger than that of the low pressure compressor44, and the low pressure turbine 46 may have a pressure ratio that isgreater than about five (5:1). The low pressure turbine 46 pressureratio may be measured prior to the inlet of the low pressure turbine 46as related to the pressure at the outlet of the low pressure turbine 46prior to an exhaust nozzle. It should be understood, however, that theabove parameters are exemplary of various embodiments of a suitablegeared architecture engine and that the present disclosure contemplatesother gas turbine engines including direct drive turbofans. A gasturbine engine may comprise an industrial gas turbine (IGT) or a gearedengine, such as a geared turbofan, or non-geared engine, such as aturbofan, a turboshaft, or may comprise any gas turbine engine asdesired.

In various embodiments, the low pressure compressor 44, the highpressure compressor 52, the low pressure turbine 46, and the highpressure turbine 54 may comprise one or more stages or sets of rotatingblades and one or more stages or sets of stationary vanes axiallyinterspersed with the associated blade stages but non-rotating aboutengine central longitudinal axis A-A′. The compressor and turbinesections 24, 28 may be referred to as rotor systems. Within the rotorsystems of the gas turbine engine 20 are multiple rotor disks, which mayinclude one or more cover plates or minidisks. Minidisks may beconfigured to receive balancing weights or inserts for balancing therotor systems.

Various components of gas turbine engine 20 may include one or moresheet structures. A sheet structure may include a relatively flatstructure having a fairly broad surface relative to its thickness. Forexample, a sheet structure may have a thickness between 10 thousandthsof an inch (0.0.254 millimeters) and 0.5 inches (12.7 millimeters), orbetween 15 thousandths of an inch (0.0.381 millimeters) and 250thousandths of an inch (6.35 millimeters).

Conventional processes for manufacturing such sheet structures arerelatively expensive and time-consuming. Referring to FIG. 2, a method200 for forming a sheet structure using a cold-spray process is shown.Formation of a sheet structure using the method 200 may be lessexpensive and less time-consuming than conventional processes. Invarious embodiments, the method 200 may be used to form sheet structureshaving a relatively large size. For example, the method 200 may be usedto form sheet structures having a surface area of at least 1 inchsquared (1 in.², 2.54 centimeters squared (cm²)), 10 in.² (25.4 cm²), 36in.² (91.44 cm²), or 100 in.² (254 cm²).

In block 202, a computer is used to create a model of a tool. A computermay include a processor, a memory, and input device, and an outputdevice. A computer may include one or more computers having processorsand one or more tangible, non-transitory memories and be capable ofimplementing logic. The processor(s) can be a general purpose processor,a digital signal processor (DSP), an application specific integratedcircuit (ASIC), a field programmable gate array (FPGA), a graphicalprocessing unit (GPU), or other programmable logic device, discrete gateor transistor logic, discrete hardware components, or any combinationthereof. The memory may be any non-transitory memory capable of storingdata. For example, the memory may store instructions to be executed bythe processor, may store modeling software, may store a model of acomponent, or the like. The input device may include, for example, amouse, a keyboard, a microphone, or the like. The output device mayinclude, for example, a display, a speaker, an input/output port, or thelike.

The tool may include a formation surface on which a material of thesheet structure is deposited. In that regard, the tool may be modeledsuch that the formation surface corresponds to a desired shape of thesheet structure. The tool may be modeled using any three-dimensionalmodeling software such as SolidWorks™, available from Dassault Systemesof Vélizy-Villacoublay, France.

The tool may include any material having sufficient yield strength toresist the formation in response to receiving spray from a cold-spraygun. As will be described below, a cold-spray deposition techniquedelivers material at a relatively low temperature. Accordingly, the toolmay include materials having a relatively low thermal resistance, whichmay result in lower cost of the tools. For example, the tool may includea metal, a plastic, or another compound material such as nylon,polymers, high-temperature resins, aluminum, low melt alloys, or thelike. A low melt alloy may include any metallic alloy that has a meltingtemperature of 450 degrees Fahrenheit (450 degrees F., 233 degreesCelsius (C)) or below. For example, a low melt alloy may include one ormore of bismuth, lead, tin, cadmium, indium, and the like. Selection ofa material for the tool may be based considering the cost of thematerial of the tool and a durability of the tool.

In block 204, a robot is controlled to form the tool based on thecomputer-generated model. The tool may be formed using additivemanufacturing, such as stereolithography. In that regard, the robot maybe an additive manufacturing device, such as a 3-D printer, connected tothe computer. The computer may be electrically coupled to the additivemanufacturing device such that the device forms the tool based on themodel. In various embodiments, the robot may include a machine separatefrom the additive manufacturing device and may independently control theadditive manufacturing device based on the computer-generated model. Invarious embodiments, a user may receive the model from the computer andmay manually provide information corresponding to the model to anadditive manufacturing device.

In block 206, an interface coating may be applied to the formationsurface of the tool. The interface coating may include, for example, ametal formed on the formation surface using electroplating. Theinterface material may include, for example, an epoxy or low melt alloy.In that regard, the interface coating may provide various benefits suchas erosion protection of the tool, thermal protection of the tool,generation of a desired surface finish or feature, facilitation ofseparation of the sheet structure from the tool, and increased rigidityand resistance to deformation resulting from contact with relativelyhigh-velocity spray from a cold-spray gun. In that regard, the formationsurface of the tool may include one or both of the interface material orthe material of the tool.

In various embodiments, it may be desirable to form one or morefeatures, such as ribs, in the sheet structure that have great thicknessrelative to other portions of the sheet structure. In order to form thefeature, a portion of the formation surface may be removed to form oneor more recess in the formation surface in block 208. In response to thesheet structure material being cold-sprayed onto the formation surface,additional material may collect in the recess such that thecorresponding part of the sheet structure has a greater thickness at thelocation corresponding to the recess. In various embodiments, the toolmay be formed to have the recess such that removal of a portion of theformation surface is optional.

In block 210, at least one layer of material may be cold-sprayed ontothe formation surface (or the interface coating) using a cold-spraydeposition technique that utilizes a cold-spray gun. A cold-spraydeposition technique is based on direct additive deposition of finemetallic particles that are accelerated to supersonic speeds using inertgas and a cold-spray gun. Inert gas may include at least one of an inertgas, air, or a less reactive gas, such as nitrogen. The cold-spray gunoutputs a gas that includes the metallic particles and the inert gas.The output gas is directed towards the formation surface. The kineticenergy used in the process enables bonding of the metallic particles toeach other on the formation surface of the tool, allowing the metallicparticles to bind together to form the sheet structure. In variousembodiments, the inert gas may be heated to a temperature that isbetween 400 degrees F. (204.4 degrees C.) and 1000 degrees F. (537.8degrees C.). The temperature of the inert gas may, however, remainsignificantly below the melting point of the material of the metallicparticles. In this context, significantly may refer to 5 percent (5%),or 15%, or 25%.

In various embodiments, it may be desirable for the sheet structure tohave a greater relative thickness at particular locations. In thatregard, the cold-spray gun may be used to apply more of the metallicparticles to the particular locations to increase the thickness at theparticular locations.

In various embodiments, the cold-spray gun may be controlled by at leastone of a computer or a robot. In that regard, the computer or robot maybe programmed to spray a predetermined amount of the metallic particlesat each location of the sheet structure. The predetermined amount of themetallic particles sprayed at each location may result in each locationof the sheet structure achieving the desired thickness.

Using a computer, and an electromechanical control system that iscontrolled by the computer, to control the cold-spray gun may result ina relatively accurate deposition of the metallic particles. The computer(or a user) may control such deposition factors as rate of discharge ofthe metallic particles, a distance from the tool from which thecold-spray gun is used, and the rate of movement of the cold-spray gunrelative to the tool to adjust the thickness of the sheet structure.

A cold-spray gun outputs a relatively narrow plume of the output gas.This relatively narrow plume results in an ability to precisely positionthe metallic particles where desired.

The metallic particles used to form the sheet structure may includevarious metals and corresponding alloys such as, for example, titaniumor titanium alloys, nickel or nickel alloys, aluminum or aluminumalloys, titanium aluminized alloys, cobalt alloys, iron, or the like.

In block 212, the at least one layer of material (corresponding to thesheet structure) may be removed from the formation surface. This sheetstructure may be removed in a variety of manners. In variousembodiments, the sheet structure may be physically manipulated away fromthe formation surface by applying a force to the sheet structure in adirection away from the formation surface. In various embodiments, thisphysical manipulation may be performed by a user grasping a portion ofthe sheet structure, may be performed by a user using a tool, such as acrowbar, to separate the sheet structure from the tool, or the like. Invarious embodiments, the tool may be constructed such that introductionof pressurized fluid causes flexure of the tool (potentially includingthe formation surface), thus facilitating release of the sheetstructure. In various embodiments, water or another fluid may beintroduced between the formation surface and the sheet structure viacapillary action or other means. In that regard, the fluid may be frozen(and thus expand), exerting a separating force/pressure to facilitaterelease of the sheet structure.

In various embodiments, a releasing agent may be applied between thesheet structure and the tool to facilitate release of the sheetstructure from the formation surface. The release agent may include, forexample, Boron Nitride (i.e., a hexagonal boron nitride) or anothersimilar release agent. The release agent may be applied between thesheet structure and the formation surface or between the formationsurface and the interface coating prior to cold-spray deposition of themetallic particles or after cold-spray deposition of the metallicparticles. The properties of the release agent may result in a weakerbond between the sheet structure and the tool, allowing the sheetstructure to be removed from the tool with relative ease. In variousembodiments, the release agent may be used and the sheet structure maystill be physically manipulated away from the formation surface.

In various embodiments, the combination of the tool and the sheetstructure may be heated to such a temperature that the sheet structuredoes not deform yet the tool, or interface coating, deforms or de-bondsfrom the sheet structure, facilitating release of the sheet structure.In various embodiments, the interface coating may include an adhesivehaving a melting point above that of the temperature of the cold-spraygas and below that of the sheet structure. In that regard, the sheetstructure and the interface coating may be heated to the melting pointof the interface coating, facilitating release of the sheet structure.The interface coating may then be reapplied to the tool prior to a newsheet structure being formed on the tool.

In various embodiments, the sheet structure may be etched from the tool.For example, an acid such as a Bronsted-Lowry acid or another etchingagent or chemically reactive material may be applied to the tool,thereby etching the tool away from the sheet structure.

In various embodiments, additional operations may be performed on thesheet structure to complete the part after separation from the tool. Forexample, the additional operations may include machining of interfaces,welding of the part to additional parts, forming an integral portion ofthe sheet structure using a cold-spray deposition technique with adifferent tool, or the like.

Turning now to FIG. 3, a system 300 for implementing the method 200 ofFIG. 2 is shown. The system 300 includes a computer 302 in communicationwith an additive manufacturing machine 304 and a robot 306. In variousembodiments, the robot 306 may not be present in the system 300. Invarious embodiments, the tool may be made using a machine different fromthe additive manufacturing machine 304.

A user may create a model of a tool using the computer 302. In variousembodiments, the model may be received by the robot 306 and/or theadditive manufacturing machine 304 which may, in turn, form a tool 308.In various embodiments, a user may provide the model to the robot 306and/or the additive manufacturing machine 304. In various embodiments, auser may manually control the additive manufacturing machine 304 tocreate the tool 308.

The tool 308 may then be provided to an electroplating machine 310 oranother device, which may apply an interface coating 312 on the tool308. In various embodiments, the electroplating machine 310 may not bepresent in the system 300 such that no interface coating is applied. Invarious embodiments, the interface coating 312 may be applied viabrushing, spraying, or another device. In various embodiments, theelectroplating machine 310 may be controlled by the computer 302 or byanother computer or robot to form the interface coating 312.

After the interface coating 312 is applied to the tool 308, the combinedtool 308 and interface coating 312 may be subjected to spray from acold-spray gun 314. The cold-spray gun 314 may direct a gas withmetallic particles 316 towards the tool 308 and the interface coating312. The gas with metallic particles 316 may hit the interface coating312 and may begin to form one or more layer of material 318 on theinterface coating 312. In various embodiments, the cold-spray gun 314may be controlled by the computer 302 and/or by a robot 315. In variousembodiments, the cold-spray gun 314 may be controlled by a separatecomputer or may be independently controlled.

After the material 318 has been applied to the interface coating 312,the combined tool 308, interface coating 312, and material 318 may besubjected to a separating means 320. The separating means 320 mayinclude any method or structure used to separate the material 318 fromthe interface coating 312 as described above with reference to block 212of FIG. 2. The separating means 320 may separate the material 318 fromthe interface coating 312. The resulting material 318 may correspond toa sheet structure 322.

Referring now to FIGS. 4A and 4B, an exemplary tool 400 and sheetstructure 401 is shown. The tool 400 has a formation surface 402. Theformation surface 402 has a shape that corresponds to a desired shape ofthe sheet structure 401. The tool 400 includes one or more pockets 404positioned within the tool 400 and having a material that is differentfrom the remaining material of the tool 400. The pockets 404 may bedesigned to reduce the likelihood of deformation of the tool 400 due toimpact with a relatively high velocity gas from a cold-spray gun 410. Inthat regard, the pockets 404 may include a material having a yieldstrength that is greater than that of the remaining portions of the tool400. For example, the pockets 404 may include an epoxy or a low meltalloy.

An interface coating 406 may be applied to the formation surface 402 ofthe tool 400. The interface coating 406 may provide benefits asdescribed above with reference to FIG. 2.

A cold-spray gun 410 may deposit metallic particles onto the interfacecoating 406 to form one or more layer of material 408. In order todeposit metallic particles onto the interface coating 406, thecold-spray gun 410 may move relative to the tool 400. For example, thecold-spray gun 410 may move from a first location 412 to a secondlocation 414, depositing metallic particles at desired thicknesses alongthe way.

After the desirable amount of material 408 has been applied to theinterface coating 406, the material 408 may be separated from theinterface coating 406 in one or more manners as described above withreference to FIG. 2.

Referring now to FIGS. 4A, 4B, and 4C, the material 408 that isseparated from the interface coating 406 may be the sheet structure 401.As shown, the sheet structure 401 has a shape that corresponds to theshape of the formation surface 402. The sheet structure 401 may have athickness 416 that corresponds to the amount of metallic particlesdeposited on the interface coating 406. The cold-spray gun 410 mayachieve the desired thickness 416 in one or more of a variety ofmanners. For example, the desired thickness 416 may be achieved bymaking a predetermined number of passes over the formation surface 402with the cold-spray gun 410, may be achieved by adjusting the rate offlow of gas exiting the cold-spray gun 410, may be achieved by adjustingthe rate at which the cold-spray gun 410 moves relative to the formationsurface 402, or the like.

Turning now to FIGS. 5A and 5B, another tool 500 may include a formationsurface 502 on which at least one layer of material 508 is directlydeposited to form a sheet structure 501. Stated differently, the tool500 may not include an interface coating. The formation surface 502 mayhave a shape that is similar to the formation surface 402 of FIG. 4A.However, it may be desirable for the sheet structure 501 to have one ormore feature 518 such as a rib.

In order to form the feature 518, a portion 519 of the formation surface502 may be removed from the tool 500 to form a recess 520. In variousembodiments, a tool that includes an interface coating may bemanipulated such that a portion of the interface coating and/or theformation surface 502 is removed from the tool to form the feature onthe sheet structure. In various embodiments, the tool 500 may be formedwith the recess 520 in place such that the tool 500 may be used withoutremoval of any of the tool 500.

After the portion 519 of the formation surface 502 is removed, acold-spray gun 510 may deposit metallic particles on the formationsurface 502. In various embodiments, the cold-spray gun 510 may bemanipulated across the formation surface 502 to deposit additionalmaterial within the recess 520. In various embodiments, the recess 520may have particular features that facilitate bonding of the metallicparticles within the recess 520. For example, the recess 520 may have anangle 522 that is greater than 90 degrees. The angle 522 may allow themetallic particles to bond together and entirely fill the recess 520.

In response to the sheet structure 501 being separated from theformation surface 502, the metal that was deposited in the recess 520may form the feature 518 such as the rib. In various embodiments, therecess 520 may not be completely filled by the material. In that regard,the sheet structure 501 may have an indentation, or a volume, where therecess 520 is not completely filled.

Turning now to FIG. 6A, a method 600 for forming a metallic structurehaving a secondary component integrated therewith is shown. In block602, a main tool may be formed. The main tool may have a main formationsurface that corresponds to a desired shape of the metallic structure.In that regard, the main tool may be formed in a similar manner as thetool described above with reference to FIG. 2.

In various embodiments, the main formation surface of the main tool maybe designed to receive the secondary component. For example, the mainformation surface may define a volume having a shape that corresponds tothe secondary component such that the volume may receive the secondarycomponent. In various embodiments, the secondary component may bepartially or wholly positioned within the volume.

In block 604, the secondary component may be positioned in the volume.If no volume is provided, the secondary component may be positioned onthe main formation surface. Positioning the secondary component in thevolume reduces the likelihood of movement of the secondary componentrelative to the formation surface in response to cold-spray beingapplied to the secondary component and the main formation surface.

In various embodiments, it may be desirable for empty space to bepresent between at least a part of the secondary component and themetallic structure. In block 606, a secondary tool may be positioned onthe secondary component. The secondary tool may have a shape thatcorresponds to the desired empty space between the part of the secondarycomponent and the metallic structure. The secondary tool may be formedin a similar manner as the main tool.

In block 608, a layer of material may be deposited using a cold-spraygun. The material may be deposited in a similar manner as describedabove with reference to FIG. 2. The material may be deposited on atleast a portion of the secondary component and the main formationsurface. If a secondary tool is used, the material may also be depositedon the secondary tool. The material may be the same metal used in thesecondary component or may be a different metal. It is desirable for thematerial to have properties that allow bonding with the material of thesecondary component.

The layer of material on the main formation surface forms the metallicstructure. In response to the material being deposited on the portion ofthe secondary component, the material bonds with the secondarycomponent. Thus, the secondary component is bonded to and integral withthe layer of material after the cold-spray deposition.

In block 610, the layer of material may be removed from the mainformation surface. This may be performed in a similar manner asdescribed above with reference to FIG. 2.

In block 612, the secondary tool may be removed from between the layerof material and the secondary component to form the metallic structurehaving the secondary component integrally attached thereto. In variousembodiments, it may be desirable for the removable tool to be leachablefrom its location between the secondary component and the metallicstructure. In that regard, the material of the secondary tool may beselected such that the secondary tool may be leached from the metallicstructure. The secondary tool may include a metallic or a nonmetallicmaterial. For example, the removable tool may include a nickel. Inresponse to exposure to an acid, such as nitric acid, exposed surfacesof the nickel become etched away via the nitric acid. As anotherexample, the secondary tool may include an alumina silica material.

As yet another example, the secondary tool may include a metal having alower melting temperature than that of the secondary component and thelayer of material. The structure that includes the secondary tool, thesecondary component, and the layer of material may be heated to atemperature that is at or above the melting temperature of the secondarytool and below the melting temperature of the secondary component andthe layer of material. In that regard, the secondary tool may melt andseparate from the secondary component and the layer of material.

In various embodiments, the secondary tool may be positioned such thatit may be physically manipulated away from the secondary component andthe layer of material. In that regard, a tool, such as a crowbar, may beused to physically manipulate the secondary tool away from the secondarycomponent and the layer of material.

Turning to FIG. 6B, a method 650 for removing a secondary tool from aspace between a secondary component and a layer of deposited material isshown. In various embodiments, the method 650 may be used in place ofblock 612 of FIG. 6A. The method 650 may be used when the secondary toolis at least partially enclosed within a space defined by the layer ofmaterial and the secondary component.

In block 652, a hole may be formed in the layer of material and/or thesecondary component. The hole may be formed using a hole forming devicesuch as a drill, an acid for etching the hole, or the like.

In block 654, the secondary tool may be leached from between thesecondary component and the layer of material via the hole. Thisleaching may be performed by heating the structure to or above themelting temperature of the secondary tool, by etching, or the like.

It may be undesirable for the hole to remain after the secondary toolhas been leached. In that regard, in block 656, the hole may be sealedafter the secondary tool is removed. For example, additional materialmay be welded to the layer of material or the secondary component aboutthe hole, a patch may be applied about the hole, or the like.

Referring now to FIG. 7A, a main tool 700 may be provided for forming ametallic structure having a secondary component integrally attachedthereto. The main tool 700 may include a main formation surface 702having a shape that corresponds to a desired shape of at least a portionof the metallic structure.

The main formation surface 702 may define a volume 704. The volume 704has a shape that corresponds to a shape of a secondary component 706. Inparticular, the secondary component 706 has a bonding surface 710, towhich material will be deposited, and a tool surface 711. The toolsurface 711 is designed to be in contact with the portion of the mainformation surface 702 that defines the volume 704.

The bonding surface 710 may define a space 707. It may be desirable forno material to be positioned within the space 707 in the final metallicstructure with the secondary component. In that regard, a secondary tool708 may be provided that has a shape corresponding to the space 707.

Turning to FIG. 7B, the secondary tool 708 may be positioned within thevolume 704, and the secondary tool 708 may be positioned within thespace 707 defined by the bonding surface 710 of the secondary component706. At this point, a cold-spray gun 709 may deposit a layer of material712. The layer of material 712 may be deposited on the main formationsurface 702. The layer of material 712 may also be deposited on aportion of the bonding surface 710 that is exposed. The layer ofmaterial 712 may also be deposited on the secondary tool 708. Inresponse to the layer of material 712 being deposited on the bondingsurface 710, the material may bond to the bonding surface 710, thusattaching the layer of material 712 to the secondary component 706.

Turning to FIG. 7C, the layer of material 712 and the secondarycomponent 706 may be removed from the main tool 700 to form a metallicstructure with a secondary component 701. It may be desirable to removethe secondary tool 708 from the space 707. In that regard, a holeforming device 714 (i.e., a punch, a dowel, a pin, a drill, an acid foretching, or the like) may be used to form a hole 716 in the layer ofmaterial 712 to create an opening between the space 707 and asurrounding environment.

Referring to FIGS. 7C and 7D, the secondary tool 708 may be leached fromthe space 707 via the hole 716. For example, the secondary tool 708 maybe etched from the space 707 via the hole 716, may be melted and drainedfrom the space 707 via the hole 716, or the like. It may be desirablefor the hole 716 to be replaced with material. In that regard, FIG. 7Dillustrates the completed metallic structure with the secondarycomponent 701 with the hole 716 sealed.

Turning to FIG. 8A, another main tool 800 may be used for forminganother metallic structure with a secondary component. In particular,the main tool 800 includes a main formation surface 802 that defines avolume 804. A secondary component 806 may be designed to be attached tothe metallic structure. In that regard, the secondary component 806 mayinclude a bonding surface 808 for receiving the deposited material and atool surface 809 designed to be in contact with the portion of the mainformation surface 802 that defines the volume 804.

The bonding surface 808 may have a texture 810 to increase bonding withthe deposited material. The texture 810 includes a raised circle 812 anda plurality of raised lines 814. In that regard, in response to materialbeing deposited on the bonding surface 808, the material will bond toall sides of the raised circle 812 and the raised lines 814. In variousembodiments, the texture 810 may also or instead include scoring,dimpling, shot-peen, integral features such as pins or other raisedshapes, or the like.

The secondary component 806 may have a base 816 that is to be positionedproximate to the metallic structure and an outer end 818 that is to bepositioned distal to the metallic structure. In order to increasestrength of the bond with the metallic structure, the base 816 may havea distance 820 that is greater than a distance 822 of the outer end 818.The relatively large distance 820 of the base 816 results in the bondingsurface 808 having a relatively large area for bonding to the metallicstructure.

Turning now to FIG. 8B, the secondary component 806 may be positionedwithin the volume 804. It may be desirable for no space to be presentbetween the secondary component 806 and the metallic structure. In thatregard, the secondary component 806 may not define a space and asecondary tool may not be used. A cold-spray gun 824 may deposit a layerof material 826 on the main formation surface 802 and on the bondingsurface 808 of the secondary component 806. The layer of material 826may bond to the bonding surface 808, including the texture 810 of theformation surface.

Turning now to FIG. 8C, the main tool 800 may be separated from thelayer of material 826 and the secondary component 806, resulting in ametallic structure with a secondary component 801 integrally attachedthereto.

While the disclosure is described with reference to exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted withoutdeparting from the spirit and scope of the disclosure. In addition,different modifications may be made to adapt the teachings of thedisclosure to particular situations or materials, without departing fromthe essential scope thereof. The disclosure is thus not limited to theparticular examples disclosed herein, but includes all embodimentsfalling within the scope of the appended claims.

Benefits, other advantages, and solutions to problems have beendescribed herein with regard to specific embodiments. Furthermore, theconnecting lines shown in the various figures contained herein areintended to represent exemplary functional relationships and/or physicalcouplings between the various elements. It should be noted that manyalternative or additional functional relationships or physicalconnections may be present in a practical system. However, the benefits,advantages, solutions to problems, and any elements that may cause anybenefit, advantage, or solution to occur or become more pronounced arenot to be construed as critical, required, or essential features orelements of the disclosure. The scope of the disclosure is accordinglyto be limited by nothing other than the appended claims, in whichreference to an element in the singular is not intended to mean “one andonly one” unless explicitly so stated, but rather “one or more.”Moreover, where a phrase similar to “at least one of a, b, or c” is usedin the claims, it is intended that the phrase be interpreted to meanthat a alone may be present in an embodiment, b alone may be present inan embodiment, c alone may be present in an embodiment, or that anycombination of the elements a, b and c may be present in a singleembodiment; for example, a and b, a and c, b and c, or a and b and c.Different cross-hatching is used throughout the figures to denotedifferent parts but not necessarily to denote the same or differentmaterials.

Systems, methods and apparatus are provided herein. In the detaileddescription herein, references to “one embodiment”, “an embodiment”, “anexample embodiment”, etc., indicate that the embodiment described mayinclude a particular feature, structure, or characteristic, but everyembodiment may not necessarily include the particular feature,structure, or characteristic. Moreover, such phrases are not necessarilyreferring to the same embodiment. Further, when a particular feature,structure, or characteristic is described in connection with anembodiment, it is submitted that it is within the knowledge of oneskilled in the art to affect such feature, structure, or characteristicin connection with other embodiments whether or not explicitlydescribed. After reading the description, it will be apparent to oneskilled in the relevant art(s) how to implement the disclosure inalternative embodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element herein is to be construed under theprovisions of 35 U.S.C. 112(f), unless the element is expressly recitedusing the phrase “means for.” As used herein, the terms “comprises”,“comprising”, or any other variation thereof, are intended to cover anon-exclusive inclusion, such that a process, method, article, orapparatus that comprises a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus.

What is claimed is:
 1. A system for forming a metallic structure havinga secondary component, comprising: a main tool having a main formationsurface corresponding to a desired shape of the metallic structure and asecondary tool having a secondary shape corresponding to the secondarycomponent; the secondary component configured to be positioned in avolume defined by the main formation surface and the volume having thesecondary shape corresponding to the secondary component, the secondarycomponent having a tool surface configured to contact the main formationsurface that defines the volume; a cold-spray gun configured to output agas including particles of a material towards the main formationsurface, the secondary component, and the secondary tool at a velocitysufficiently great to cause the particles of the material to bondtogether and to the secondary component on the main formation surface toform a layer of material resulting in the metallic structure with thesecondary component attached thereto, wherein the layer of material andthe secondary component are removed from the main tool to form themetallic structure; wherein the secondary tool is configured to bepositioned on the secondary component such that the cold-spray gun isconfigured to deposit at least a portion of the layer of material on thesecondary tool; and a device for removing the secondary tool.
 2. Thesystem of claim 1, wherein the secondary component has a bonding surfaceconfigured to receive the layer of material, the bonding surface beingtextured to enhance bonding with the layer of material.
 3. The system ofclaim 2, wherein the device for removing the secondary tool isconfigured to form a space between at least a portion of the secondarycomponent and the layer of material.
 4. The system of claim 3, furthercomprising a hole-forming device configured to form a hole in the layerof material wherein the device for removing the secondary tool isconfigured to remove the secondary tool via the hole in the layer ofmaterial.
 5. The system of claim 1, wherein the metallic structure is asheet structure having a surface area of at least 1 inch squared.
 6. Thesystem of claim 1, wherein the main tool comprises a metal, a plastic,nylon, polymers, high-temperature resins, aluminum, or low melt alloys.7. The system of claim 1, wherein a portion of the main formationsurface is removed to form one or more recess in the main formationsurface.
 8. The system of claim 1, further comprising a releasing agentconfigured to be applied between the metallic structure and the maintool to facilitate release of the metallic structure from the mainformation surface.
 9. The system of claim 1, wherein the secondarycomponent comprises a base positioned proximate to the metallicstructure and an outer end positioned distal to the metallic structure.